Air handler with a leak free controls enclosure

ABSTRACT

An air handler configured with a second enclosure disposed within the first enclosure to create a continuous airflow passageway, wherein access to the second enclosure does not interrupt the continuous airflow passageway.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is related to, and claims the priority benefit of, U.S. Provisional Patent Application Ser. No. 61/861,116 filed Aug. 1, 2013, the contents of which are hereby incorporated in their entirety into the present disclosure

TECHNICAL FIELD OF THE DISCLOSED EMBODIMENTS

The presently disclosed embodiments generally relate to heating, ventilation and air conditioning (HVAC) equipment, and more particularly, an air handler with a leak free controls enclosure.

BACKGROUND OF THE DISCLOSED EMBODIMENTS

In a typical residential, ducted heating, ventilation, and air conditioning (“HVAC”) system, a single blower in an indoor air handler circulates air to various parts of the home through a system of ducts. Any service or diagnostic performance of such air handlers typically requires the removal of at least one casing panel, or door of the enclosure to expose the fan, controls and other electrical components. Removal of this panel either renders the air handler inoperable, or allows ambient air to enter the airflow passageway; thus, altering the operational characteristics of the air handler while service is being performed. This configuration may alter the performance of the air handler while diagnostics or service is attempted to be performed. Moreover, the controls and other electrical components may be exposed to the moist, conditioned air as it passes through the airflow passageway, depending on the orientation of the air handler. There is, therefore, a need for an air handler with a separate enclosure for the controls and other electrical components that isolates these items from the airflow passageway.

SUMMARY OF THE DISCLOSED EMBODIMENTS

In one aspect, an air handler with a leak free controls enclosure is provided. The air handler includes a first enclosure including a first interior volume. The air handler also includes a second enclosure including a second interior volume, wherein the second enclosure may be affixed to the first enclosure such that the second interior volume may be disposed within the first interior volume to create a continuous airflow passageway, wherein access to the second enclosure interior volume does not interrupt the continuous airflow passageway.

In one embodiment, the air handler includes a fan and a coil disposed within the first interior volume. In one embodiment, the coil is configured to allow a refrigerant to flow therethrough.

In one embodiment, the second enclosure may be affixed to the first enclosure above the coil. In one embodiment, the second enclosure may be affixed to the first enclosure via at least one fastener. In one embodiment, an insulation material may be affixed to at least one exterior side of the second enclosure. In one embodiment, the insulation material may be a foam material. In one embodiment, at least one panel of the second enclosure may be removable.

In one embodiment, the air handler includes at least one component disposed within the second interior volume. In one embodiment, the at least one component may be in operable communication with the fan. In one embodiment, the at least one component may be operative to control the fan to cause air to move through the first enclosure.

In another aspect an HVAC system including an air handler with a leak free controls enclosure is provided. The HVAC system includes an air handler with a leak free controls enclosure operatively coupled to an outdoor unit assembly. In one embodiment, the air handler and the outdoor unit assembly are configured to circulate a refrigerant therethrough. In one embodiment, the outdoor unit assembly unit may be a heat pump, while in another embodiment, the outdoor unit assembly may be an air conditioner. In one embodiment, the HVAC system includes at least one conduit coupled to the air handler to distribute air into an interior space.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments and other features, advantages and disclosures contained herein, and the manner of attaining them, will become apparent and the present disclosure will be better understood by reference to the following description of various exemplary embodiments of the present disclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 schematically illustrates an air handler unit of the present disclosure with the leak free controls enclosure and the front panels removed;

FIG. 2 is an exploded view of an air handler with a leak free controls enclosure;

FIG. 3 is a perspective view of an air handler unit with a leak free controls enclosure with the controls enclosure panel removed; and

FIG. 4 schematically illustrates an HVAC system using an air handler with a leak free controls enclosure.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.

FIG. 1 illustrates a schematic view of an embodiment of the present disclosure, indicated generally at 10. The air handler with a leak free controls enclosure 10 includes a first enclosure 12 including a first interior volume 14, and a fan 16 disposed within the first interior volume 14. In one embodiment, the air handler 10 includes an electrical heating element 18 disposed within the first interior volume 14 to provide auxiliary heat within the first enclosure 12. In one embodiment, the air handler 10 includes a coil 20 disposed within the first interior volume 14. In one embodiment, the coil 20 is configured to allow a refrigerant to flow therethrough.

As shown in FIG. 2, the air handler 10 also includes a second enclosure 22 including a second interior volume 26, wherein the second enclosure 22 may be affixed to the first enclosure 12 such that the second interior volume 26 may be disposed within the first interior volume 14. In one embodiment, the second enclosure 22 may be affixed to the first enclosure 12 above the coil 20. In one embodiment, the second enclosure 22 may be affixed to the first enclosure 12 via at least one fastener 28. In one embodiment, an insulation material 30 may be affixed to at least one exterior side of the second enclosure 22. In one embodiment, the insulation material 30 may be a foam material, or fiber-glass to name a couple of non-limiting examples. As the second enclosure 22 is affixed to first enclosure 12, the insulation material 30 creates a sealed airflow passageway through first interior volume 14 of the air handler 10. In one embodiment, at least one panel 32 of the second enclosure 22 may be removable. In one embodiment, the air handler 10 includes a second enclosure 22, having a second enclosure interior volume 26, disposed within a first enclosure 12 to create a continuous airflow passageway; wherein access to the second enclosure interior volume 26 does not interrupt the continuous airflow passageway.

In one embodiment, as shown in FIG. 3, the air handler 10 also includes at least one component 34 disposed within the second interior volume 26. In one embodiment, the at least one component 34 may be a controller, to name one non-limiting example. In one embodiment, the at least one component 34 may be in operable communication with the fan 16. In one embodiment, the at least one component 34 may be operative to control the fan 16 to cause air to move through the first enclosure 12. When the at least one panel 32 is removed from the second enclosure 22, access may be gained to the at least one component 34 without disrupting the sealed airflow passageway within the first interior volume 14.

FIG. 4 illustrates a schematic view of an embodiment of a HVAC system, generally indicated at 36. The HVAC system 36 includes an air handler with a leak free controls enclosure 10 operatively coupled to an outdoor unit assembly 38 via a conduit circuit 40. The air handler 10 and the outdoor unit assembly 38 are configured to circulate a refrigerant therethrough. In one embodiment, outdoor unit assembly unit 38 may be a heat pump, while in another embodiment, outdoor unit assembly 38 may be an air conditioner, to name just two non-limiting examples. In one embodiment. the HVAC system 36 includes at least one conduit 42 coupled to the air handler 10 to distribute air into an interior space 44.

In an exemplary embodiment of the HVAC system 36, the at least one component 34 receives a signal from a sensor designating a demand to condition the interior space 44. The demand to condition the interior space 44 may come from one or multiple sensors (not shown) placed throughout the interior space 44. For example, when a demand call is initiated, the at least one component 34 may send a signal to the outdoor unit assembly 38 to begin circulating the refrigerant through the conduit circuit 40 to the coil 20. Once the refrigerant has circulated through the coil 20 for a specified period of time, the at least one component 34 may send an electrical signal to begin rotating the fan 16 to circulate air. The fan 16 circulates the conditioned air from the first interior volume 14 to the interior space 44, via conduit 42, to satisfy the demand. After the demand is satisfied, controller 34 may send an electrical signal to remove power from fan 16. The at least one component 34 additionally sends an electrical signal to the outdoor unit assembly 38 to stop circulating the refrigerant.

If auxiliary heating is required, power is supplied by the at least one component 34 to an auxiliary heating component (not shown) positioned above the air handler 10. The at least one component 34 sends a signal to begin rotating fan 16 to circulate air. The fan 16 circulates the conditioned air through the first interior volume 14 to the interior space 44, via conduit 42, to satisfy the demand. After the demand is satisfied, the at least one component 34 sends an electrical signal to remove power from the auxiliary heating component (not shown). The at least one component 34 also sends an electrical signal to remove power from fan 16. It will be appreciated that other auxiliary components may be added to the HVAC system 36 for humidification, de-humidification, ventilation, etc.

It will be appreciated that access may be gained to the at least one component 34, while the air handler 10 is operating, by removing the at least one panel 32 from the second enclosure 22 without disrupting the airflow passageway through the first interior volume 14. It will also be appreciated that, access to the fan 16 may be gained by removal of the second enclosure 22.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. 

What is claimed is:
 1. An air handler comprising: a first enclosure having a first interior volume; a second enclosure having a second interior volume; and wherein the second enclosure is affixed to the first enclosure such that the second interior volume is disposed within the first interior volume;
 2. The air handler of claim 1, further comprising: at least one component disposed within the second interior volume; a fan disposed within the first interior volume; wherein the at least one component is in operable communication with the fan; and wherein the at least one component is operative to control the fan to cause air to move through the first enclosure.
 3. The air handler of claim 1, further comprising a coil disposed within the first interior volume.
 4. The air handler of claim 3, wherein the coil is configured to allow a refrigerant to flow therethrough.
 5. The air handler of claim 4, wherein the second enclosure is affixed to the first enclosure above the coil.
 6. The air handler of claim 1, wherein the second enclosure is affixed to the first enclosure via at least one fastener.
 7. The air handler of claim 1, wherein an insulation material is affixed to at least one exterior side of the second enclosure.
 8. The air handler of claim 7, wherein the insulation material comprises a foam material.
 9. The air handler of claim 1, wherein at least one side of the second enclosure is removable.
 10. The air handler of claim 2, wherein the at least one component comprises a controller.
 11. An HVAC system comprising: an air handler comprising: a first enclosure having a first interior volume; a coil disposed within the first interior volume; and a second enclosure having a second interior volume; wherein the second enclosure is affixed to the first enclosure such that the second interior volume is disposed within the first interior volume; wherein the air handler is disposed inside an interior space.
 12. The HVAC system of claim 11, further comprising an outdoor unit assembly operatively coupled to the air handler for exchange of a refrigerant therebetween.
 13. The HVAC system of claim 11, further comprising at least one conduit affixed to the air handler to distribute air to the interior space.
 14. The HVAC of claim 11, wherein the second enclosure is affixed to the first enclosure via at least one fastener.
 15. The HVAC system of claim 11, wherein the second enclosure is affixed to the first enclosure above the coil.
 16. The HVAC system of claim 11, wherein an insulation material is affixed to at least one exterior side of the second enclosure.
 17. The HVAC system of claim 16, wherein the insulation material comprises a foam material.
 18. The HVAC system of claim 11, wherein at least one side of the second enclosure is removable.
 19. An air handler comprising: a first enclosure having a first enclosure interior volume; a second enclosure, having a second enclosure interior volume, disposed within the first enclosure to create a continuous airflow passageway; wherein access to the second enclosure interior volume does not interrupt the continuous airflow passageway. 